Porous ultra-high molecular weight polyethylene (UHMWPE) is a high performance bioinert polymer used in cranio-facial reconstructive surgery in procedures where relatively low mechanical stresses arise. As an alternative to much stiffer and costly polyether-ether-ketone (PEEK) polymer, UHMWPE finds further wide application in hierarchically structured hybrids for advanced implants mimicking cartilage, cortical and trabecular bone tissues within a single component. The mechanical behaviour of open-cell UHMWPE sponges obtained through sacrificial desalination of hot compression-moulded UHMWPE-NaCl powder mixtures shows a complex dependence on the fabrication parameters and microstructural features. In particular, similarly to other porous media it displays significant inhomogeneity of strain that readily localises within deformation bands that govern the overall response. In this article, we report advances in the development of accurate experimental techniques for operando studies of the structure-performance relationship applied to the porous UHMWPE medium with pore sizes of about 250 µm that are most well-suited for live cell proliferation and fast vascularization of implants. Samples of UHMWPE sponges were subjected to in situ compression using a micromechanical testing device within Scanning Electron Microscope (SEM) chamber, allowing the acquisition of high-resolution image sequences for Digital Image Correlation (DIC) analysis. Special masking and image processing algorithms were developed and applied to reveal the evolution of pore size and aspect ratio. Key structural evolution and deformation localisation phenomena were identified at both macro- and micro-structural levels in the elastic and plastic regimes. The motion of pore walls was quantitatively described, and the presence and influence of strain localisation zones were revealed and analysed using DIC technique.

The structure of self-reinforced composites (SRCs) based on ultra-high molecular weight 21 polyethylene (UHMWPE) was studied by means of Wide-Angle X-Ray Scattering (WAXS), X-Ray 22 tomography, Raman spectroscopy, Scanning Electron Microscopy (SEM) and in situ tensile testing 23 in combination with advanced processing tools like Avizo, ImageJ, and Ncorr to determine the cor-24 relation between the processing conditions, on the one hand, and the molecular structure and 25 mechanical properties, on the other. SRCs were fabricated by hot compaction of UHMWPE fibers at 26 different pressure and temperature combinations without addition of polymer matrix or softener. 27 It was found by WAXS that higher compaction temperatures led to more extensive melting of 28 fibers with the corresponding reduction of the Herman’s factor reflecting the degree of molecular 29 orientation, while the increase of hot compaction pressure suppressed the melting of fibers within 30 SRCs at a given temperature. X-Ray tomography proved the absence of porosity while polarized 31 light Raman spectroscopy measurements for both longitudinal and perpendicular fiber orienta-32 tions showed qualitatively the anisotropy of SRC samples. SEM revealed that the matrix was 33 formed by interlayers of molten polymer entrapped between fibers in SRCs. Moreover, in situ 34 tensile tests demonstrated the increase of Young’s modulus and tensile strength with increasing 35 temperature.